U.S. patent application number 17/544014 was filed with the patent office on 2022-06-23 for position sensor system and method.
The applicant listed for this patent is Melexis Technologies SA. Invention is credited to Bruno BRAJON, Gael CLOSE, Christian SCHOTT.
Application Number | 20220196435 17/544014 |
Document ID | / |
Family ID | |
Filed Date | 2022-06-23 |
United States Patent
Application |
20220196435 |
Kind Code |
A1 |
SCHOTT; Christian ; et
al. |
June 23, 2022 |
POSITION SENSOR SYSTEM AND METHOD
Abstract
A position sensor system is arranged for determining a position
of a sensor device movable along a predefined path relative to a
magnetic source. The system includes the magnetic source and the
sensor device. The magnetic source has a first plurality of
magnetic pole pairs arranged along a first track and a second
plurality of magnetic pole pairs arranged along a second track,
centrelines of the tracks are spaced apart by a predefined track
distance. The sensor device is configured for measuring at least
two orthogonal magnetic field components at a first sensor
location, and at least two second orthogonal magnetic field
components at a second sensor location. The first and second sensor
location are spaced apart by a predefined sensor distance smaller
than the predefined track distance, in a direction transverse to
the tracks.
Inventors: |
SCHOTT; Christian; (Bevaix,
CH) ; CLOSE; Gael; (Bevaix, CH) ; BRAJON;
Bruno; (Bevaix, CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Melexis Technologies SA |
Bevaix |
|
CH |
|
|
Appl. No.: |
17/544014 |
Filed: |
December 7, 2021 |
International
Class: |
G01D 5/14 20060101
G01D005/14; G01D 5/244 20060101 G01D005/244 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 23, 2020 |
EP |
20217151.8 |
Claims
1. A position sensor system for determining a position of a sensor
device movable along a predefined path relative to a magnetic
source or vice versa, the position sensor system comprising: said
magnetic source comprising a first plurality of magnetic pole pairs
arranged along a first track having a first periodicity (or pole
distance), and comprising a second plurality of magnetic pole pairs
arranged along a second track having a second periodicity different
from the first periodicity, wherein a centreline of the first track
is spaced from a centreline of the second track by a predefined
track distance; said sensor device being configured for measuring a
first set of a least two orthogonal magnetic field components at a
first sensor location, and for measuring a second set of at least
two orthogonal magnetic field components at a second sensor
location, wherein the first sensor location is spaced from the
second sensor location by a predefined sensor distance smaller than
the predefined track distance, in a direction transverse to the
tracks; and wherein the sensor device further comprises a
processing unit configured for determining said position based on
at least some of the measured signals.
2. The position sensor system according to claim 1, wherein the
predefined sensor distance is 20% to 80% of the predefined track
distance.
3. The position sensor system according to claim 1, wherein the
predefined sensor distance is at most 75% of the predefined track
distance.
4. The position sensor system according to claim 1, wherein the
predefined sensor distance is at least 20% of the predefined track
distance.
5. The position sensor system according to claim 1, wherein the
position sensor system is an angular position sensor system.
6. The position sensor system according to claim 5, wherein the
magnetic source is rotatable about a rotation axis; and wherein the
first track and the second track are concentric circular tracks
located in a single plane perpendicular to the rotation axis.
7. The position sensor system according to claim 5, wherein the
magnetic source is rotatable about a rotation axis and wherein the
first track and the second track are cylindrical tracks about said
rotation axis, and spaced apart along said rotation axis; wherein
the first track has a first outer radius , and the second track has
a second outer radius equal to the first outer radius.
8. The position sensor system according to claim 5, wherein the
first number of pole pairs is a value in the range from 4 to 15;
and wherein the second number of pole pairs is a value in the range
from 5 to 16.
9. The position sensor system according to claim 1, wherein the
position sensor system is a linear position sensor system; and
wherein the first track is the first linear segment, and the second
track is the second linear segment parallel to the first linear
segment.
10. The position sensor system according to claim 1, wherein the
processing unit is configured for: estimating a transverse position
of the sensor device relative to the magnetic tracks, based on at
least some of the measured magnetic field components; and
determining the position of the sensor device based on at least
some of the measured magnetic field components and based on the
estimate transverse position.
11. The position sensor system according to claim 1, wherein the
processing unit is configured for: calculating a first set of
quadrature components and a second set of quadrature components
based on at least some of the measured components, using a
predefined set of coefficients; and determining the position of the
sensor device based on the first and second set of quadrature
components.
12. The position sensor system according to claim 1, wherein the
processing unit is configured for: estimating a transverse position
of the sensor device relative to the magnetic tracks, based on at
least some of the measured components, and determining a set of
coefficients based on the estimated transverse position; and
calculating a first set of quadrature components and a second set
of quadrature components based on at least some of the measured
components, using the set of coefficients determined in step b);
determining the position of the sensor device based on the first
and second set of quadrature components.
13. A method of determining a position of a sensor device movable
along a predefined path relative to a magnetic source or vice
versa, the magnetic source comprising a first plurality of magnetic
pole pairs arranged along a first track having a first periodicity,
and comprising a second plurality of magnetic pole pairs arranged
along a second track having a second periodicity different from the
first periodicity, wherein centrelines of the tracks are spaced
apart by a predefined track distance, the method comprising: a)
measuring at least two orthogonal magnetic field components at a
first sensor location, and measuring at least two orthogonal
magnetic field components at a second sensor location, spaced from
the first sensor location by a predefined sensor distance smaller
than the predefined track distance in a direction transverse to the
tracks; b) determining the position of the sensor device based on
at least some of the measured magnetic field components.
14. The method according to claim 13, wherein step a) comprises: i)
measuring at least two or at least three orthogonal magnetic field
components at a first sensor location, and ii) measuring at least
two or at least three orthogonal magnetic field components at a
second sensor location, spaced from the first sensor location by a
predefined sensor distance smaller than the predefined track
distance in a direction transverse to the tracks; and wherein step
b) comprises: i) estimating a transverse position of the sensor
device relative to the tracks based on at least some of the
measured magnetic field components; ii) determining the position of
the sensor device based on at least some of the measured magnetic
field components and based on the estimated transverse
position.
15. The method according to claim 13, wherein step b) comprises: i)
calculating a first set of quadrature components and a second set
of quadrature components based on at least some of the measured
magnetic field components, using a set of equations with a
predefined set of coefficients; ii) determining the position of the
sensor device based on the first and second set of quadrature
components.
Description
FIELD OF THE INVENTION
[0001] The present invention relates in general to the field of
magnetic sensor systems and magnetic sensor devices and methods of
determining a position, and more in particular to linear and
angular position sensor systems, linear and angular position sensor
devices, and methods of determining a linear or an angular
position.
BACKGROUND OF THE INVENTION
[0002] Magnetic sensor systems, in particular angular position
sensor systems are known in the art. They offer the advantage of
being able to measure an angular position without making physical
contact, thus avoiding problems of mechanical wear, scratches,
friction, etc.
[0003] Many variants of position sensor systems exist, addressing
one or more of the following requirements: using a simple or cheap
magnetic structure, using a simple or cheap sensor device, being
able to measure over a relatively large range, being able to
measure with great accuracy, requiring only simple arithmetic,
being able to measure at high speed, being highly robust against
positioning errors, being highly robust against an external
disturbance field, providing redundancy, being able to detect an
error, being able to detect and correct an error, having a good
signal-to-noise ratio (SNR), etc.
[0004] Often two or more of these requirements conflict with each
other, hence a trade-off needs to be made.
[0005] There is always room for improvements or alternatives.
SUMMARY OF THE INVENTION
[0006] It is an object of embodiments of the present invention to
provide a position sensor system, a position sensor device, and a
method of determining a position of a sensor device relative to a
magnetic source having a plurality of magnetic poles.
[0007] It is an object of embodiments of the present invention to
provide such a system and device and method, which provide an
improved accuracy.
[0008] It is an object of embodiments of the present invention to
provide such a system and device and method, which are suitable for
use in an industrial and/or automotive environment.
[0009] It is an object of embodiments of the present invention to
provide such a position sensor system, wherein the cost of the
position sensor device is reduced (e.g. smaller chip area).
[0010] It is an object of embodiments of the present invention to
provide such a position sensor system, wherein the semiconductor
substrate of the position sensor device has a reduced
footprint.
[0011] It is an object of embodiments of the present invention to
provide such a position sensor system, wherein the mounting
requirements of the sensor device are relaxed.
[0012] It is an object of embodiments of the present invention to
provide such a position sensor system, that is more robust against
ageing effects, (e.g. related to misalignment, mechanical
wear).
[0013] It is an object of embodiments of the present invention to
provide such a position sensor system, requiring a less powerful
processor, and/or requiring less processing power.
[0014] It is an object of embodiments of the present invention to
provide such a position sensor system, requiring less storage space
(e.g. to store a lower number of coefficients).
[0015] It is an object of embodiments of the present invention to
provide such a position sensor system, which is substantially
insensitive to an external disturbance field.
[0016] These and other objectives are accomplished by embodiments
of the present invention.
[0017] According to a first aspect, the present invention provides
a position sensor system for determining a position of a sensor
device movable along a predefined path relative to a magnetic
source or vice versa, the position sensor system comprising: said
magnetic source comprising a first plurality (N1) of magnetic pole
pairs arranged along a first track having a first periodicity, and
comprising a second plurality (N2) of magnetic pole pairs arranged
along a second track having a second periodicity different from the
first periodicity, wherein a centreline of the first track is
spaced from a centreline of the second track by a predefined track
distance; said sensor device being configured for measuring a first
set of a least two orthogonal magnetic field components (e.g. By1,
Bz1) at a first sensor location, and for measuring a second set of
at least two orthogonal magnetic field components (e.g. By2, Bz2)
at a second sensor location, wherein the first sensor location is
spaced from the second sensor location by a predefined sensor
distance smaller than the predefined track distance, e.g. at least
20% smaller, in a direction transverse to the tracks (e.g.
substantially perpendicular to the tracks); and wherein the sensor
device further comprises a processing unit configured for
determining said position based on at least some of the measured
signals.
[0018] It is a major advantage of this system that the dimensions
of the sensor device, in particular the distance between the sensor
elements can be chosen independent from the distance between the
tracks of the magnetic source. This makes it possible (inter alia)
to optimise the magnetic sensor device and the magnetic source
independent from each other.
[0019] It is a major advantage of the system that the distance
between the sensor elements is smaller than the distance between
the tracks of the magnetic source, because this allows the size and
the costs of the semiconductor substrate of the sensor device to be
reduced.
[0020] It is an advantage of this system wherein the magnetic
source comprises a first track with the first periodicity and a
second track with the second periodicity, instead of only a single
track with multiple periodicities, because the latter is more
difficult (and thus more expensive) to produce.
[0021] The magnetic source may be or may comprise one or more
permanent magnets or may be formed as a monolithic piece of
magnetic material or may be composed of two monolithic pieces of
magnetic material, such as for example two linear strips, or two
magnetic rings mounted together.
[0022] In an embodiment, a ratio of the first number of pole pairs
(N1) and the second number of pole pairs (N2) is (N-1)/N, where N
is an integer number in the range from 5 to 32, preferably in the
range from 5 to 16, for example N1=4 and N2=5, or N1=5 and N2=6, or
N1=6 and N2=7, or . . . , or N1=31 and N2=21.
[0023] In an embodiment, a ratio of the first number of pole pairs
(N1) and the second number of pole pairs (N2) is (N-2)/N, where N
is an odd integer number in the range from 5 to 31, preferably in
the range from 5 to 17, for example N1=5 and N2=7, or N1=7 and
N2=9, or N1=9 and N2=11, or N1=11 and N2=13, or N1=13 and N2=15, or
N1=15 and N1=17, or N=17 and N2=19, or N1=19 and N2=21, or N1=21
and N2=23, or N1=23 and N2=25, or N1=25 and N2=27, or N1=27 and
N2=29, or N1=29 and N2=31.
[0024] In an embodiment, the magnetic source comprises two rings of
magnetic material, spaced from each other by a layer or a zone of a
non-magnetic material, such as e.g. plastic or ceramic or a
non-magnetic metal or alloy, e.g. aluminum or copper. The
non-magnetic material may have a thickness of at least 0.5 mm, or a
thickness in the range from about 0.5 mm to 1.5 mm. In case the two
rings are concentric rings arranged as shown in FIG. 15(a), they
may each have a width (in the radial direction) of about 2.0 mm to
about 5.0 mm. In case the two rings having the same radius, and are
arranged as shown in FIG. 15(b), they may each have a width (in the
axial direction) of about 2.0 to about 5.0 mm.
[0025] In an embodiment, the magnetic source comprises two
substantially linear strips of magnetic material, spaced from each
other by a layer or a zone of a non-magnetic material. The
non-magnetic material may have a thickness of at least 0.5 mm, or a
thickness in the range from about 0.5 mm to 1.5 mm. Alternatively,
the two strips are separated from each other by means of
groove.
[0026] In an embodiment, the predefined sensor distance is 20% to
80% of the predefined track distance. Or in other words, a ratio of
the sensor distance "ds" over the track distance "dt" is a value in
the range from 20% to 80%.
[0027] In an embodiment, the predefined sensor distance (ds) is a
value in the range from 1.0 to 3.0 mm, or in the range from 1.5 mm
to 2.5 mm, and the predefined track distance (dt) is at least 20%
or at least 30% or at least 40% or at least 50% or at least 60% or
at least 70% or at least 80% or at least 90% larger than the
predefined sensor distance.
[0028] In an embodiment, the predefined sensor distance (ds) is at
most 75% of the predefined track distance (dt), or at most 70%, or
at most 65%, or at most 60%.
[0029] In an embodiment, the ratio (ds/dt) is at most 80%, or at
most 75%, or at most 70%, or at most 65%, or at most 60%, or at
most 65%, or at most 50%, or at most 45%, or at most 40%, or at
most 35%, or at most 30%, or at most 25%, or at most 20%.
[0030] In an embodiment, the predefined sensor distance (ds) is at
least 20% of the predefined track distance (dt), or at least 25%,
or at least 30%, or at least 35%, or at least 40%, or at least 45%,
or at least 50%.
[0031] In an embodiment, the ratio (ds/dt) is at least 20%, or at
least 25%, or at least 30%, or at least 35%, or at least 40%, or at
least 45%, or at least 50%.
[0032] In an embodiment, the position sensor system is an angular
position sensor system.
[0033] In an embodiment, the measurement range is 360.degree..
[0034] In an embodiment, the magnetic source is rotatable about a
rotation axis; and the first track and the second track are
concentric circular tracks located in a single plane perpendicular
to the rotation axis.
[0035] In this embodiment, the first track T1 has a first, circular
centerline with a first radius, and the second track T2 has a
second, circular centerline with a second radius, and the
difference between the first and the second radius is equal to the
predefined track distance "dt".
[0036] In this embodiment, preferably, the first sensor position P1
and to second sensor position P2 are located on a virtual line
passing through the rotation axis, this virtual line is preferably
parallel to the plane containing the first track and the second
track, for example as illustrated in FIG. 15(a).
[0037] In an embodiment, the magnetic source is rotatable about a
rotation axis; and the first track and the second track are
cylindrical tracks about said rotation axis and spaced apart along
said rotation axis; and the first track (T1) has a first outer
radius (R1), and the second track (T2) has a second outer radius
(R2) equal to the first outer radius.
[0038] In this embodiment, preferably, the first sensor position
and to second sensor position are located on a virtual line
parallel to the rotation axis, for example as illustrated in FIG.
14(b).
[0039] In an embodiment, the first number (N1) of pole pairs is a
value in the range from 4 to 15; and the second number (N2) of pole
pairs is a value in the range from 5 to 16.
[0040] In an embodiment, the first number (N1) of pole pairs is a
value in the range from 4 to 7, and the second number (N2) of pole
pairs is a value in the range from 5 to 8.
[0041] In an embodiment, the position sensor system is a linear
position sensor system; and the first track is the first linear
segment, and the second track is a second linear segment parallel
to the first linear segment.
[0042] In this embodiment, preferably the first sensor position and
to second sensor position are located on a virtual line
perpendicular to the first and second linear segments, for example
as illustrated in FIG. 15(c).
[0043] In an embodiment, the processing unit is configured for: b)
estimating a transverse position of the sensor device relative to
the magnetic tracks, based on at least some of the measured
magnetic field components; and c) for determining the position of
the sensor device based on at least some of the measured magnetic
field components and based on the estimate transverse position.
[0044] The "transverse position" is a radial position in the
example of FIG. 15(a) or FIG. 15(b) and is a lateral position in
the example of FIG. 15(c). Such a method is illustrated e.g. in
FIG. 11.
[0045] In an embodiment, the processing unit is configured for: b)
calculating a first set of quadrature components and a second set
of quadrature components based on at least some of the measured
components using a predefined set of coefficients; and c) for
determining the position of the sensor device based on the first
and second set of quadrature components.
[0046] Step b) may comprise calculating each of said quadrature
components as a weighted sum of only two of the measured magnetic
field components, for example as illustrated in FIG. 4. Thus, in
this embodiment, only two weighting factors are required for each
quadrature component, i.e. a total of only eight coefficients.
[0047] It is an advantage of this embodiment that the set of
coefficients is predetermined, for example stored in non-volatile
memory before actual use of the sensor device.
[0048] In an embodiment, the sensor device comprises a non-volatile
memory, and the set of coefficients are stored in said non-volatile
memory.
[0049] The coefficients may be determined by performing a
calibration test after mounting of the sensor device relative to
the magnet and determining an optimal set of coefficients based on
the measurements performed during the calibration test. This may
considerably relax the mounting tolerances, and/or improve the
accuracy of the position sensor system.
[0050] In an embodiment, the number of coefficients is at most
eight.
[0051] In an embodiment, the processing unit is configured for: b)
estimating a transverse position of the sensor device relative to
the magnetic tracks, based on at least some of the measured
components, and for determining a set of coefficients based on the
estimated transverse position; and c) for calculating a first set
of quadrature components and a second set of quadrature components
based on at least some of the measured components, using the set of
coefficients determined in step b); d) determining the position of
the sensor device based on the first and second set of quadrature
components.
[0052] It is an advantage of this embodiment that the set of
coefficients is dynamically determined or dynamically adjusted as a
function of the transverse position, e.g. caused by mechanical
mounting tolerances or by mechanical drift or wear. In this way,
the accuracy of the absolute position can be improved. This dynamic
recalibration may be performed by the sensor device itself, for
example periodically, and/or may be initiated for example by an
external processor.
[0053] In an embodiment, the transverse position of the sensor
device is determined based on a ratio of one or more of |Bx1|/|Bz|
or |Bx1|/|By1| or|By1|/|Bz1| or |Bx2|/|Bz2| or |Bx2|/|By2| or
|By2|/|Bz2| at one or more predefined positions (e.g. estimated
using an initial set of coefficients), or may be based on a maximum
ratio of of one or more of |Bx1|/|Bz1| or |Bx1|/|By1| or
|By1|/|Bz1| or |Bx2|/|Bz2| or |Bx2|/|By2| or |By2|/|Bz2| at a
random position over a full rotation, or may be based on the value
of the gradient |dBx/dx| at one or more angular positions (e.g. as
illustrated in FIG. 16) or in an angular subrange, or may be based
on the maximum value of the gradient |dBx/dx| over the measurement
range.
[0054] According to a second aspect, the present invention also
provides a method of determining a position of a sensor device
movable along a predefined path relative to a magnetic source or
vice versa, the magnetic source comprising a first plurality of
magnetic pole pairs arranged along a first track having a first
periodicity, and comprising a second plurality of magnetic pole
pairs arranged along a second track having a second periodicity
different from the first periodicity, wherein centrelines of the
tracks are spaced apart by a predefined track distance, the method
comprising the steps of: a) measuring at least two orthogonal
magnetic field components (e.g. By1, Bz1) at a first sensor
location, and measuring at least two orthogonal magnetic field
components (e.g. By2, Bz2) at a second sensor location, spaced from
the first sensor location by a predefined sensor distance smaller
than the predefined track distance in a direction transverse to the
tracks (e.g. substantially perpendicular to the tracks); b)
determining the position of the sensor device based on at least
some of the measured magnetic field components.
[0055] In an embodiment, one of the measured magnetic field
components is tangential to the direction of relative movement
(typically indicated as "By" in this application).
[0056] In an embodiment, step a) comprises: measuring at least two
(e.g. By1, Bz1) or at least three (e.g. Bx1, By1, Bz1) orthogonal
magnetic field components at a first sensor location, and measuring
at least two (e.g. By2, Bz2) or at least three (e.g. Bx2, By2, Bz2)
orthogonal magnetic field components at a second sensor location,
spaced from the first sensor location by a predefined sensor
distance smaller than the predefined track distance in a direction
transverse to the tracks (e.g. substantially perpendicular to the
tracks); and wherein step b) comprises: i) estimating a transverse
position (e.g. offset) of the sensor device relative to the tracks
based on at least some of the measured magnetic field components;
ii) determining the position of the sensor device based on at least
some of the measured magnetic field components and based on the
estimated transverse position.
[0057] In an embodiment, step b) comprises: i) calculating a first
set of quadrature components and a second set of quadrature
components based on at least some of the measured magnetic field
components using a set of equations with a predefined set of
coefficients; ii) determining the position of the sensor device
based on the first and second set of quadrature components.
[0058] In an embodiment, the set of equations comprises or consists
of four equations.
[0059] In an embodiment, the set of equations comprises or consists
of four polynomial equations.
[0060] In an embodiment, the set of equations comprises or consists
of four linear equations.
[0061] In an embodiment, the set of equations comprises or consists
of four linear equations, each with only two terms and two
coefficients (or weighting factors).
[0062] According to another aspect, the present invention is also
directed to a position sensor device, configured for performing any
of the methods of FIG. 11 or FIG. 13 or FIG. 14, or variants
thereof using magnetic field gradients, as described in the
detailed description.
[0063] Particular and preferred aspects of the present invention
are set out in the accompanying independent and dependent claims.
Features from the dependent claims may be combined with features of
the independent claims and with features of other dependent claims
as appropriate and not merely as explicitly set out in the
claims.
[0064] These and other aspects of the invention will be apparent
from and elucidated with reference to the embodiment(s) described
hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] FIG. 1(a) shows a conceptual perspective view of an angular
position sensor system according to an embodiment of the present
invention, showing a magnetic source with at least two tracks
comprising a plurality of poles, and a sensor device capable of
measuring two or three orthogonal field components at two sensor
locations.
[0066] FIG. 1(b) shows an enlarged view of a portion of FIG. 1(a),
furthermore showing a centreline of the first track and of the
second track, spaced apart by a predefined track distance.
[0067] FIG. 1(c) shows in more detail the relative position of the
sensor device of FIG. 1(b) relative to the two tracks. The drawing
also shows a radial direction R, a tangential direction T and an
axial direction A with respect to the magnetic source.
[0068] FIG. 2(a) shows a mathematical model of the magnetic source,
which was used in a computer simulation. In the example shown, the
magnetic source comprises two concentric rings located in a single
plane. The drawing also shows a radial direction R, a tangential
direction T and an axial direction A with respect to the magnetic
source. FIG. 2(a) also shows a second orthogonal coordinate system
connected to the sensor device, and containing axes X, Y, Z. As can
be seen, A is parallel to Z, T is parallel to Y, and R is parallel
to X.
[0069] FIG. 2(b) is a top view showing an orthogonal projection of
possible locations of the first sensor element above the inner ring
(or inner track) of the magnetic source.
[0070] FIG. 2(c) is a top view showing an orthogonal projection of
possible locations of the second sensor element above the outer
ring (or outer track) of the magnetic source.
[0071] FIG. 2(d) shows an enlarged cross-sectional view of the two
tracks and the two sensor locations shown in the example of FIG.
2(a), in a plane containing the axes A and R. As can be seen, the
first sensor position is located above the inner ring, and the
second sensor position is located above the outer ring, and both
sensor positions are located between the centrelines of the inner
and outer ring. The specific values provided are of course only an
example.
[0072] FIG. 3(a) is a graph obtained by computer-simulation,
showing the amplitude of the magnetic field component Bz oriented
in the axial direction of an exemplary magnetic source having ten
pole pairs on its outer ring, and having eight pole pairs on its
inner ring.
[0073] FIG. 3(b) is a graph obtained by computer-simulation,
showing the amplitude of the magnetic field component By oriented
in the circumferential direction, tangential to the direction of
relative movement.
[0074] FIG. 3(c) is a graph obtained by computer-simulation,
showing the amplitude of the magnetic field component Bx oriented
in the radial direction, perpendicular to the direction of relative
movement.
[0075] FIG. 4 shows a set of equations that may be used in certain
embodiments of the present invention to convert measured magnetic
field components into two sets of quadrature components.
[0076] FIG. 5(a) shows a graph with waveforms of two orthogonal
magnetic field components By1, Bz1, as can be measured at the first
sensor location. The amplitude is shown in arbitrary units as a
function of the mechanical position of the sensor device. As can be
seen, these measured signals have a periodicity of
360.degree./4=90.degree..
[0077] FIG. 5(b) shows a graph with two quadrature waveforms Bsin1,
Bcos1 as can be derived from the measured signals Byl, Bz1 using a
transformation, e.g. using the set of equations shown in FIG.
4.
[0078] FIG. 5(c) shows a graph illustrating a typical error (in
degrees) between a calculated angular position al based on the set
of quadrature signals shown in FIG. 5(b), and the actual position.
The amplitude is shown in degrees as a function of the angular
position of the sensor device.
[0079] FIG. 6(a) shows a graph with waveforms of two orthogonal
magnetic field components By2, Bz2, as can be measured at the
second sensor location. The amplitude is shown in arbitrary units
as a function of the mechanical position of the sensor device. As
can be seen, these measured signals have a periodicity of
360.degree. /5=72.degree. .
[0080] FIG. 6(b) shows a graph with two quadrature waveforms Bsin2,
Bcos2 as can be derived from the measured signals By2, Bz2 using a
transformation, e.g. using the set of equations shown in FIG.
4.
[0081] FIG. 6(c) shows a graph illustrating a typical error (in
degrees) between a calculated angular position a2 based on the sets
of quadrature signals shown in FIG. 6(b), and the actual position.
The amplitude is shown in degrees as a function of the angular
position of the sensor device.
[0082] FIG. 7(a) shows a waveform illustrating the angular error
between the actual angular position, and an angular position al
calculated based on the set of quadrature signals (Bsin1, Bcos1)
derived from the signals (Byl, Bz1) measured at the first sensor
location (above the inner track) by using the same linear
transformation as in FIG. 5(b) with the same coefficients, in case
of a radial misposition of 0.1 mm.
[0083] FIG. 7(b) shows a waveform illustrating the angular error
between the actual angular position, and an angular position a2
calculated based on the set of quadrature signals (Bsin2, Bcos2)
derived from the signals (By2, Bz2) measured at the second sensor
location (above the outer track) by using the same linear
transformation as in FIG. 6(b) with the same coefficients, in case
of a radial misposition of 0.1 mm.
[0084] FIG. 8(a) to FIG. 8(h) show examples of sensor devices with
various sensor structures as may be used in embodiments of the
present invention.
[0085] FIG. 8(a) shows a schematic representation of a sensor
device comprising two magnetic sensors structures spaced apart over
a predefined distance Ax, each sensor structure comprising four
horizontal Hall elements arranged near the periphery of an
integrated magnetic flux concentrator (IMC). Each sensor structure
is capable of measuring three orthogonal components Bx, By, Bz.
[0086] FIG. 8(b) shows another sensor device comprising two
magnetic sensors structures spaced apart over a predefined distance
Ax, each sensor structure comprising one horizontal Hall element
(for measuring Bz) and two vertical Hall elements (for measuring Bx
and By respectively).
[0087] FIG. 8(c) shows another sensor device comprising two
magnetic sensors structures spaced apart over a predefined distance
Ax, each sensor structure comprising only two horizontal Hall
elements arranged on opposite sides of an IMC disk and located on a
virtual line perpendicular to the X-axis. Each sensor structure is
capable of measuring two orthogonal components By, Bz.
[0088] FIG. 8(d) shows another sensor device comprising two
magnetic sensors structures spaced apart over a predefined distance
Ax, each sensor structure comprising one horizontal Hall element
and one vertical Hall element. Each sensor structure is capable of
measuring two orthogonal components By, Bz.
[0089] FIG. 8(e) to FIG. 8(h) show variants of the sensor devices
of FIG. 8(a) to FIG. 8(d) respectively, each comprising four sensor
structures spaced apart in the X and in the Y-direction.
[0090] FIG. 9 shows a high-level block-diagram of a sensor device
as can be used in embodiments of the present invention.
[0091] FIG. 10 to FIG. 14 show flow-charts of methods of
determining a linear or angular position, of a sensor device
relative to a magnetic source, proposed by the present
invention.
[0092] FIG. 15(a) to FIG. 15(c) illustrate embodiments of position
sensor systems as proposed by the present invention, in perspective
view.
[0093] FIG. 15(a) shows an angular position sensor system
comprising a magnetic source comprising two concentric tracks
located in a single plane, and a sensor device arranged above or
below that plane.
[0094] FIG. 15(b) shows an angular position sensor system
comprising a magnetic source comprising two circular tracks
arranged on a cylindrical surface, and a sensor device arranged as
a satellite around that cylinder.
[0095] FIG. 15(c) shows a linear position sensor system comprising
a magnetic source comprising two linear parallel tracks located in
a single plane, and a sensor device arranged above that plane. Also
shown is an orthogonal coordinate system connected to the magnetic
source, comprising an axial direction A, a longitudinal direction
L, and a transverse direction T.
[0096] FIG. 16 is a duplicate of FIG. 3(c), with information
added.
[0097] The drawings are only schematic and are non-limiting. In the
drawings, the size of some of the elements may be exaggerated and
not drawn on scale for illustrative purposes. Any reference signs
in the claims shall not be construed as limiting the scope. In the
different drawings, the same reference signs refer to the same or
analogous elements.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0098] The present invention will be described with respect to
particular embodiments and with reference to certain drawings, but
the invention is not limited thereto but only by the claims. The
drawings described are only schematic and are non-limiting. In the
drawings, the size of some of the elements may be exaggerated and
not drawn on scale for illustrative purposes. The dimensions and
the relative dimensions do not correspond to actual reductions to
practice of the invention.
[0099] Furthermore, the terms first, second and the like in the
description and in the claims, are used for distinguishing between
similar elements and not necessarily for describing a sequence,
either temporally, spatially, in ranking or in any other manner. It
is to be understood that the terms so used are interchangeable
under appropriate circumstances and that the embodiments of the
invention described herein are capable of operation in other
sequences than described or illustrated herein.
[0100] Moreover, the terms top, under and the like in the
description and the claims are used for descriptive purposes and
not necessarily for describing relative positions. It is to be
understood that the terms so used are interchangeable under
appropriate circumstances and that the embodiments of the invention
described herein are capable of operation in other orientations
than described or illustrated herein.
[0101] It is to be noticed that the term "comprising", used in the
claims, should not be interpreted as being restricted to the means
listed thereafter; it does not exclude other elements or steps. It
is thus to be interpreted as specifying the presence of the stated
features, integers, steps or components as referred to, but does
not preclude the presence or addition of one or more other
features, integers, steps or components, or groups thereof. Thus,
the scope of the expression "a device comprising means A and B"
should not be limited to devices consisting only of components A
and B. It means that with respect to the present invention, the
only relevant components of the device are A and B.
[0102] Reference throughout this specification to "one embodiment"
or "an embodiment" means that a particular feature, structure or
characteristic described in connection with the embodiment is
included in at least one embodiment of the present invention. Thus,
appearances of the phrases "in one embodiment" or "in an
embodiment" in various places throughout this specification are not
necessarily all referring to the same embodiment, but may.
Furthermore, the particular features, structures or characteristics
may be combined in any suitable manner, as would be apparent to one
of ordinary skill in the art from this disclosure, in one or more
embodiments.
[0103] Similarly, it should be appreciated that in the description
of exemplary embodiments of the invention, various features of the
invention are sometimes grouped together in a single embodiment,
figure, or description thereof for the purpose of streamlining the
disclosure and aiding in the understanding of one or more of the
various inventive aspects. This method of disclosure, however, is
not to be interpreted as reflecting an intention that the claimed
invention requires more features than are expressly recited in each
claim. Rather, as the following claims reflect, inventive aspects
lie in less than all features of a single foregoing disclosed
embodiment. Thus, the claims following the detailed description are
hereby expressly incorporated into this detailed description, with
each claim standing on its own as a separate embodiment of this
invention.
[0104] Furthermore, while some embodiments described herein include
some but not other features included in other embodiments,
combinations of features of different embodiments are meant to be
within the scope of the invention, and form different embodiments,
as would be understood by those in the art. For example, in the
following claims, any of the claimed embodiments can be used in any
combination.
[0105] In the description provided herein, numerous specific
details are set forth. However, it is understood that embodiments
of the invention may be practiced without these specific details.
In other instances, well-known methods, structures and techniques
have not been shown in detail in order not to obscure an
understanding of this description.
[0106] The term "track" as part of a magnetic source, as used
herein, typically refers to a ring-shaped or annular shaped or
cylindrical shaped object when talking about an angular position
sensor system for example as illustrated in FIG. 15(a) and FIG.
15(b), and typically refers to a beam-shaped object when talking
about a linear position sensor system, for example as illustrated
in FIG. 15(c).
[0107] The tracks of the magnetic source of FIG. 15(a), FIG. 15(b)
and FIG. 15(c) have a "width" extending in the radial direction R,
the axial direction A, and the transverse direction T,
respectively.
[0108] The term "centreline of a track" as used herein refers to a
virtual line or curve, situated at the surface of the track, in the
middle of the width. For example, in FIG. 15(a) the centreline is a
circle having a radius equal to the average of the inner radius and
the outer radius of the respective track; in FIG. 15(b) the
centreline is a circle having a radius equal to the outer radius of
the track and situated halfway the width (in the axial direction);
in FIG. 15(c) the centreline is line in the middle of the track
(halfway the transverse direction).
[0109] The expression "the tracks are spaced apart by a distance
dt" as used herein means that centrelines of the tracks are spaced
by the distance "dt", for example as illustrated in FIG. 1(c).
[0110] The expression "the sensors or sensor structures are spaced
apart by a distance ds" as used herein means that centres (or a
reference point) of the sensors or sensor structures are spaced
apart by the distance "ds", for example as illustrated in FIG.
1(c).
[0111] The present invention relates to linear and angular position
sensor systems, linear and angular position sensor devices, and
methods of determining a linear or an angular position relative to
a magnetic source, and in particular to position sensor systems
with high accuracy.
[0112] The present invention provides a position sensor system
comprising a magnetic source, and a sensor device which is movable
along a predefined path relative to the magnetic source. The
magnetic source comprises a first plurality (N1) of magnetic pole
pairs arranged along a first track having a first periodicity, and
comprises a second plurality (N2) of magnetic pole pairs arranged
along a second track having a second periodicity different from the
first periodicity. A centreline (or central line or central curve)
of the first track is spaced from a centreline (or central line or
central curve) of the second track by a predefined track distance
"dt". The sensor device comprises at least four magnetic sensitive
elements configured for measuring at least two first orthogonal
magnetic field components (typically referred to herein as: By1,
Bz1) at a first sensor location (P1), and at least two second
orthogonal magnetic field components (typically referred to herein
as: By2, Bz2) at a second sensor location (P2). The first sensor
location (P1) is spaced from the second sensor location (P2) by a
predefined sensor distance "ds". The sensor device further
comprises a processing unit configured for determining said linear
or angular position based on at least a subset of the measured
signals (e.g. based on, or based solely on Byl, Bz1, By2, Bz2).
[0113] According to an important aspect of the present invention,
the predefined sensor distance "ds" is smaller than the predefined
track distance "dt", measured in a direction transverse to the
tracks.
[0114] It is a major advantage of this system that the dimensions
of the sensor device, in particular the distance between the sensor
elements can be chosen independent of the distance between the
tracks of the magnetic source. This makes it possible (inter alia)
to optimise the magnetic sensor device and the magnetic source
independent from each other, and also allows a single sensor device
to be used in combination with various magnetic sources.
[0115] It is a major advantage of the system that the distance "ds"
between the sensor elements is smaller (e.g. at least 20% smaller)
than the distance "dt" between centrelines of the tracks of the
magnetic source, because this allows the size and the costs of the
semiconductor substrate of the sensor device to be reduced. This is
especially important in a highly competitive market.
[0116] It is an advantage of this system wherein the magnetic
source comprises a first track with the first periodicity and a
second track with the second periodicity, instead of only a single
track with multiple periodicities, because the former magnetic
source is easier to produce. For example, if the first and second
tracks are linear tracks (e.g. as illustrated in FIG. 15(c)), the
magnetic source may be composed of two magnetic strips, each of
which may be produced separately, and then arranged side by side in
the plane (e.g. as illustrated in FIG. 15(a). As another example,
if the first and second tracks are circular tracks having a same
radius but a different number of poles (e.g. as illustrated in FIG.
15(b), the magnetic source may be composed of two magnetic rings
which may be produced separately, and then arranged side-by-side
axially. As another example, if the first and second tracks are
circular tracks having a different radius and a different number of
poles (e.g. as illustrated in FIG. 15(a), the magnetic source can
be composed of two magnetic rings which may be produced separately,
and then arranged concentrically, in a plane.
[0117] Examples of such position sensor systems are shown in FIG.
15(a) to FIG. 15(c).
[0118] More specifically, FIG. 15(a) shows an angular position
sensor system 1500a comprising a magnetic source 1510a comprising
two concentric tracks T1, T2 located in a single plane, and a
sensor device 1520a arranged above or below that plane.
[0119] FIG. 15(b) shows an angular position sensor system 1500b
comprising a magnetic source 1510b comprising two circular tracks
T1, T2 arranged on a cylindrical surface, and a sensor device 1520b
arranged as a satellite around that cylindrical surface.
[0120] FIG. 15(c) shows a linear position sensor system 1500c
comprising a magnetic source 1510c comprising two linear parallel
tracks T1, T2 located in a single plane, and a sensor device 1520c
arranged above that plane.
[0121] As mentioned above, the number of magnetic pole pairs N1 of
the first track T1 is different from the number of magnetic pole
pairs of the second track. In certain embodiments, the ratio of the
first number of pole pairs (N1) and the second number of pole pairs
(N2) is (N-1)/N, where N is an integer number in the range from 5
to 32, preferably in the range from 5 to 16, for example N1=4 and
N2=5 (ratio=4/5), or N1=5 and N2=6 (ratio=5/6), or N1=6 and N2=7
(ratio=6/7), etc.
[0122] In an embodiment, a ratio of the first number of pole pairs
(N1) and the second number of pole pairs (N2) is (N-2)/N, where N
is an odd integer number in the range from 5 to 31, preferably in
the range from 5 to 17, for example N1=5 and N2=7 (ratio=5/7), or
N1=7 and N2=9 (ratio=7/9), or N1=9 and N2=11 (ratio=9/11), or N1=11
and N2=13 (ratio=11/13), or N1=13 and N2=15 (ratio=13/15), or N1=15
and N1=17 (ratio=15/17), or N1=17 and N2=19 (ratio=17/19), or N1=19
and N2=21 (ratio=19/21), or N1=21 and N2=23 (ratio=21/23), or N1=23
and N2=25 (ratio=23/25), or N1=25 and N2=27 (ratio=25/27), or N1=27
and N2=29 (ratio=27/29), or N1=29 and N2=31 (ratio=29/31).
[0123] As will be explained in more detail further, by measuring
two orthogonal magnetic field components at the first and at the
second sensor location P1, P2, it is possible to determine a unique
position relative to the magnetic source, with high accuracy.
[0124] The invention will mainly be explained referring to the
angular position sensor system shown in FIG. 15(a) for simplifying
the description, but the present invention is not limited thereto,
and the same principles also apply to other variants, mutatis
mutandis.
[0125] Referring now to the figures.
[0126] FIG. 1(a) to FIG. 1(c) show a conceptual view of an angular
position sensor system 100 corresponding to that of FIG. 15(a). In
the specific example shown, the magnetic source 110 comprises two
magnetic rings: an inner ring having N1=8 pole pairs, and an outer
ring having N2=10 pole pairs, but the present invention is not
limited thereto, and the rings may comprise another number of
magnetic pole pairs. The rings may be axially magnetised. The
example also shows a sensor device 120 capable of measuring two or
three orthogonal magnetic field components in each of two sensor
locations P1, P2, for example an axial field component in a
direction A which is parallel to the rotation axis, a radial field
component oriented in the radial direction R, and a tangential
field component oriented in a circumferential direction T,
tangential to a virtual circle.
[0127] FIG. 1(b) shows an enlarged view of a portion of FIG. 1(a)
and shows that the first magnetic track T1 is a ring with a first
inner and outer radius, and the second magnetic track T2 is a ring
with a second inner and outer radius. The first track T1 has a
first width W1, and the second track T2 as a second width W2. In
the example shown, the first width W1 and the second width W2 are
equal, but that is not absolutely required for the invention to
work, and the invention will also work if the width W1 of the first
track T1 is larger or smaller than the second width W2 of the
second track T2.
[0128] FIG. 1(c) is a perspective view illustrating the relative
position of the sensor device 120 having two sensor positions P1,
P2 relative to the magnetic tracks T1, T2. As shown, a projection
of the first and the second sensor position P1, P2 on a plane
containing the first and the second centreline 213, 214 are
preferably located on a line segment which is oriented
radially.
[0129] Contrary to what developers would normally choose, the
inventors decided not to locate the first and second sensor
position above the centrelines 213, 214, i.e. above the middle of
the tracks T1 and T2, but they decided to move the sensor locations
closer together. Indeed, as can be seen, the distance "ds" between
the projections of the first and second sensor position P1, P2 is
smaller than the distance "dt" between the centrelines 213, 214 of
the tracks. It could not be predicted beforehand whether this
solution would work at all, let alone how well the solution would
work.
[0130] While not shown FIG. 1(c), there may be a code-free region
between the first track T1 and the second track T2. This region may
for example be formed by a groove. This groove may be left open, or
may be filled with a non-magnetic material, e.g. a plastic, a
ceramic, a non-magnetic metal or alloy (e.g. to avoid accumulation
of dust or particles). Even if a code-free region is present, the
two sensor positions P1, P2 are preferably located "above" the
magnetic material, i.e. above the magnetized zones, e.g. as
illustrated in more detail in FIG. 2(d).
[0131] While the representation of FIG. 1(c) seems to suggest that
the sensor device contains a substrate and that the two sensor
positions have to be located at the top of that substrate, this is
not absolutely required, and the sensor locations P1, P2 may also
be located underneath the substrate, as may be obtained by turning
the sensor device upside-down. In this way, the sensor elements can
be closer to the tracks, the measured signals can be larger, the
signal-to-noise ratio (SNR) may be increased and/or crosstalk may
be reduced, and the overall accuracy may be improved.
[0132] FIG. 2(a) shows a mathematical model of a variant of the
magnetic source 110 of FIG. 1(a), comprising an inner ring
comprising or consisting of a magnetic material and an outer ring
comprising or consisting of magnetic material, spaced apart from
each other by a non-magnetic material (e.g. by air).
[0133] In the specific example shown in FIG. 2(a), the inner ring
211 is made of or comprises a magnetic material having an inner
radius of 7.5 mm and an outer radius of 10.5 mm, hence has a width
W1 of 3.0 mm. The outer ring 212 is made of or comprises a magnetic
material having an inner radius of 11.5 mm and an outer radius of
14.5 mm, and a width W2 of 3.0 mm. In the example, both rings have
a height (in the axial direction) of 1.0 mm. But of course, this is
only an example, and embodiments of the present invention are not
limited to these specific dimensions.
[0134] FIG. 2(a) also shows the relative position and orientation
of the sensor device 220 with respect to the magnetic source 210.
This figure also shows a first coordinate system relative to the
magnetic source comprising the axes A (axial direction), R (radial
direction), T (tangential direction), and a second coordinate
system connected to the sensor device 220, having an X-axis
corresponding to the radial direction R, a Y-axis corresponding to
the direction of relative movement, in this example the
circumferential direction T, and a Z-axis, parallel to the rotation
axis A. The sensor device 220 preferably comprises a semiconductor
substrate, and the X and Y axis are parallel to the semiconductor
substrate, and the Z-axis is orthogonal to the semiconductor
substrate.
[0135] This model was used in a computer simulation, the results of
which are described further.
[0136] FIG. 2(b) is a top view showing orthogonal projections of
the relative locations of the first sensor positions P1 on the
inner ring 211 of the magnetic source, and FIG. 2(c) is a top view
showing orthogonal projections of the relative locations of the
second sensor positions P2 on the outer ring 212 of the magnetic
source. As can be seen, these positions are not located on the
centrelines (in the middle) of the rings but are deliberately
off-center. In the particular example shown, the two sensor
positions are spaced apart by ds=1.9 mm, and the first sensor
positions P1 are located at a radius of 11.0-0.95=10.05 mm, and the
second sensor positions P2 are located at the radius of
11.0+0.95=11.95 mm, but of course the present invention is not
limited to this example, and other sensor positions may also be
used. In fact, it is not required that the distance between P1 and
the first centreline is substantially equal to the distance between
P2 and the second centreline, but in preferred embodiments that is
the case.
[0137] FIG. 2(d) shows an enlarged cross-sectional view in a plane
perpendicular to the plane in which the magnetic rings are located
and passing through the first and the second sensor location P1,
P2. As shown, the first sensor position P1 is preferably located
"vertically above" the inner ring 211, and the second sensor
position P2 is preferably located "vertically above" the outer ring
212, although this is not absolutely required, and the invention
may still work if one or both of the sensor positions P1, P2 is
located "vertically above" the non-coded region, an example of
which will be discussed in relation to FIG. 7(a) and FIG. 7(b). As
can also be seen, projections of the first and second sensor
location P1, P2 (at 10.05 and 11.95 mm) are located between the
centreline 213 of the inner ring (at 9.0 mm) and the centreline 214
of the outer ring (at 13.0 mm). It is noted that the sensor
locations of this embodiment are in fact offset quite far from the
centrelines (1.05 mm/1.50 mm=70%).
[0138] The sensor device of FIG. 2(d) may comprise at each sensor
location two or four horizontal Hall elements and a magnetic flux
concentrator (IMC), for example as shown in more detail in FIG.
8(a) to FIG. 8(d), but other sensor structures may also be used.
Such an IMC disk may have a diameter of about 0.15 to about 0.25
mm. The sensor device may be arranged at a small axial distance
from the magnetic rings, e.g. at a distance "g" in the range from
0.3 to 2.5 m, or in the range from 0.4 mm to 2.5 mm, or from 0.5 to
2.0 mm, or from 0.5 to 1.5 mm.
[0139] FIG. 3(a) is a graph obtained by a computer-simulation,
showing the amplitude of the magnetic field component Bz (=Baxial)
as would be measured by the sensor device 220 of FIG. 2(a), located
about 1 mm above the rings. The component Bz is oriented in the
axial direction of the magnetic source having ten pole pairs on its
outer ring 212 and having eight pole pairs on its inner ring 211,
which are clearly visible. The centreline 213 of the inner ring (or
magnetic track) 211, and the centreline 214 of the outer ring (or
magnetic track) 212 are indicated as white dotted circles. The
projected positions of the first and second sensor elements P1, P2
are indicated by means of black circles situated between the dotted
centrelines. As was to be expected, the signal Bz is largest above
the respective centrelines 213, 214, but degrades fast with
increasing distance from these centrelines.
[0140] FIG. 3(b) is a graph obtained by computer-simulation,
showing the amplitude of the magnetic field component By (=Btang)
tangential to the direction of relative movement, i.e. oriented in
the circumferential direction. As can be seen, there is
considerable overlap (or crosstalk) between the magnetic field
generated by the inner ring and the outer ring.
[0141] FIG. 3(c) is a graph obtained by computer-simulation,
showing the amplitude of the magnetic field component Bx (=Bradial)
oriented in a radial direction of the magnetic source,
perpendicular to the direction of relative movement. Again, there
is large overlap or crosstalk between the magnetic field created by
the inner ring and the magnetic field created by the outer
ring.
[0142] The reader will agree that it is impossible to predict
whether a position sensor system where the sensor elements are
located offset from the centrelines, will still work, let alone to
predict or even estimate how good or how bad the performance will
be. The zones indicated by 390 and 391 will be described
further.
[0143] Anyway, while not the only solution, the inventors came to
the idea of using a linear transformation to convert the measured
signals (in particular By and Bz measured at the two sensor
locations P1, P2) into two sets of quadrature signals.
[0144] FIG. 4 shows a set of linear equations that can be used in
embodiments of the present invention to convert at least some of
the measured signals of the magnetic field components, in
particular Bz (=Baxial) and By (=Btang) into two sets of quadrature
components, one set being represented by (Bsin1, Bcos1) and the
other set being represented by (Bsin2, Bcos2). From these sets, two
angles can then be calculated, for example in accordance with the
following formulas: al=arctan(Bsin1/Bcos1) and
a2=arctan(Bsin2/Bcos2).
[0145] The first angle al is indicative of an angular position of
the inner ring (in the example having a periodicity of
360.degree./4=90.degree., hence having an ambiguity of integer
multiples of 90.degree.). and the second angle a2 is indicative of
an angular position of the outer ring (in the example having a
periodicity of 360.degree./5=72.degree., thus having an ambiguity
of integer multiples of 72.degree.). The combination of the two
angles (.alpha.1, .alpha.2), however, corresponds to a unique
angular position of the sensor device relative to the magnetic
source.
[0146] The set of equations of FIG. 4 contain eight coefficients.
Suitable or optimal coefficients values a1, a2, b1, b2, c1, c2, d1,
d2 can be found by simulations, or by measurement, and by using
known techniques, such as curve-fitting techniques and/or least
mean square error techniques. It is also possible to optimize the
coefficients values for each particular assembly, e.g. by
performing measurements of a particular system during a calibration
test after assembly, and by optimizing the parameters for that
assembly, but of course that is more difficult and more expensive.
It would be more desirable if one could work with a single set of
predefined coefficients. The sensor device may comprise a
non-volatile memory 921 (see FIG. 9), and the coefficients values
may be stored in the non-volatile memory as parameters.
[0147] Experiments were performed to find out how good or how bad
the resulting position would be, in terms of accuracy.
[0148] FIG. 5(a) shows a graph with waveforms of two orthogonal
magnetic field components Bz1, By1, as can be measured at first
sensor locations P1, in the vicinity of the first track T1, more in
particular "vertically above" the inner track T1, e.g. as shown in
FIG. 2(d). The amplitude (vertical axis) is shown in arbitrary
units as a function of the mechanical position (horizontal axis) of
the sensor device. As can be seen, the signals Bz1, By1 have a
periodicity of 360.degree./4=90.degree., and the amplitude of Bz1
seems to be fairly constant, but the amplitude of By1 is not
constant.
[0149] FIG. 5(b) shows a graph with two quadrature waveforms
(Bsin1, Bcos1) as can be obtained by a linear transformation using
the set of equations shown in FIG. 4 and suitable coefficients. It
is very surprising that the curves of FIG. 5(b) look like a perfect
sine and a cosine, especially when considering the amount of
crosstalk shown in FIG. 3(b) and FIG. 3(c) and considering that the
translation is only a simple set of linear equations. In fact, it
is also possible to use higher-order polynomials, e.g. second order
or third-order polynomials.
[0150] FIG. 5(c) shows a graph illustrating a typical error (in
degrees) between the calculated angle al based on the sets of
quadrature signals (Bsin1, Bcos1) shown in FIG. 5(b), and the
actual position. The amplitude is shown in degrees as a function of
the angular position of the sensor device. It is simply amazing
that the angular position "'1" of the inner ring 211 can be
determined with an inaccuracy smaller than .+-.0.01.degree.,
despite the amount of crosstalk.
[0151] Similar simulations and calculations were performed for the
signals measured at the second sensor location P2, situated near
the outer track T2, more in particular "vertically above" the outer
track T2, e.g. as shown in FIG. 2(d).
[0152] FIG. 6(a) shows a graph with waveforms of two orthogonal
magnetic field components Bz2, By2, as can be measured at the
second sensor location P2. The amplitude (vertical axis) is shown
in arbitrary units as a function of the angular position
(horizontal axis) of the sensor device 220 relative to the magnet
210. As can be seen, these measured signals have a periodicity of
360.degree./5=72.degree..
[0153] FIG. 6(b) shows a graph with two quadrature waveforms
(Bsin2, Bcos 2) as can be derived from the measured signals (By2,
Bz2), e.g. by means of a linear transformation using the set of
equations shown in FIG. 4.
[0154] FIG. 6(c) shows a graph illustrating a typical error (in
degrees) between the calculated angle .alpha.2 based on the sets of
quadrature signals (Bsin2, Bcos2) shown in FIG. 6(b), and the
actual angular position of the sensor device 220. The error
amplitude (vertical axis) is shown in degrees as a function of the
angular position (vertical axis) of the sensor device. Again, it is
simply amazing that the angular position ".alpha.2" of the outer
ring 212 can be determined with an inaccuracy smaller than
.+-.0.02.degree., despite the considerable amount of crosstalk.
[0155] From the simulations of FIG. 5(a) to FIG. 6(c) it can be
understood that, since the angular position .alpha.1 of the sensor
device 220 with respect to the inner ring 211 can be determined
with an accuracy better than .+-.0.01.degree. (but with an
ambiguity of multiples of 90.degree., and since the angular
position .alpha.2 of the sensor device 220 with respect to the
outer ring 212 can be determined with an accuracy better than
.+-.0.02.degree. (but with an ambiguity of multiples of 72.degree.,
that the overall angular position of the sensor device 220 relative
to the magnetic source containing both rings can be determined with
an overall accuracy better than .+-.0.02.degree. (and without
ambiguity). Indeed, the overall angular position can be found e.g.
by finding a set of integer values "k1" and "k2" for which
(.alpha.1+k1)*90.degree.=(.alpha.2+)k2*72.degree.), which is equal
to the overall angular position, where k1 is an integer value
smaller smaller than N1, and k2 is an integer value smaller than
N2. Of course, other formulas to calculate the overall position may
also be used.
[0156] The inventors wanted to know what would happen if the sensor
device 220 was built or programmed with the set of coefficients
optimized for the envisioned position described above, i.e. for a
radial position of P1 at 10.05 mm and a radial position of P2 at
11.95 mm, in case of a mechanical mispositioning of 0.1 mm.
[0157] FIG. 7(a) shows a waveform similar to the waveform of FIG.
5(c), indicative for the angular error of the sensor device 220
relative to the inner ring 211, as would be obtained when applying
the linear transformation mentioned above, using the same
coefficients mentioned above (e.g. being hardcoded, or retrieved
from the non-volatile memory), in case of a mechanical
mispositioning of 0.1 mm. As can be seen, the angle .alpha.1 has a
worst-case error of about .+-.1.5.degree..
[0158] FIG. 7(b) shows a waveform similar to the waveform of FIG.
6(c), indicative for the angular error of the sensor device 220
relative to the outer ring 212, as would be obtained when applying
the linear transformation mentioned above, using the same
coefficients mentioned above (e.g. being hardcoded, or retrieved
from the non-volatile memory), in case of a mechanical
mispositioning of 0.1 mm. As can be seen, the angle .alpha.2 has a
worst-case error of about .+-.1.0.degree..
[0159] Since the angular position .alpha.1 only needs to be known
for solving the ambiguity of the outer ring, the inaccuracy of the
outer ring 212 is dominant in this case, since it has the larger
number of pole pairs. It can thus be understood that the overall
error of the overall angular position sensor system 200 using a
fixed, predefined set of coefficients would be about
.+-.1.0.degree. in case of a mispositioning of 0.1 mm, which is
acceptable for some application, but too large for some
applications.
[0160] One solution to reduce this inaccuracy is to increase the
number of pole pairs, which will typically increase the cost of the
magnetic source 210. Another solution to address this problem of
mispositioning, already suggested above, is to determine the
optimum coefficients in a calibration test, after assembling the
position sensor system, and storing the coefficients in a
non-volatile memory of the device. This works if the mispositioning
is static but does not work if the mispositioning drifts over time.
Yet another solution which also works if the mispositioning drifts
over time will be described further, when discussing FIG. 11 and
FIG. 13.
[0161] FIG. 8(a) to FIG. 8(h) show examples of sensor devices with
various sensor structures as may be used in embodiments of the
present invention.
[0162] FIG. 8(a) shows a schematic representation of a sensor
device 820a with two magnetic sensors structures spaced apart over
a predefined distance Ax along the X-axis, as can be used in
embodiments of the present invention. Each sensor structure of this
device comprises four horizontal Hall elements H1-H4 arranged near
the periphery of an integrated magnetic flux concentrator IMC. Each
sensor structure is capable of measuring three orthogonal magnetic
field components, Bx, By, Bz, as described in more detail in patent
publication EP3650816(A1) and in patent application EP20191167.4
mentioned above. In order to understand the present invention, it
suffices to know that the component Bx1 is proportional to (H1-H3),
and that the component By1 is proportional to (H2-H4), and that the
component Bz is proportional to (H1+H2) or to (H2+H4) or to
(H1+H2+H3+H4). Thus, the sensor device 820a has eight magnetic
sensor elements, and is capable of measuring two sets of three
orthogonal magnetic field components, namely (Bx1, By1, Bz1) at a
first sensor position P1, and (Bx2, By2, Bz2) at a second sensor
position P2. But the present invention is not limited to this
particular sensor device, and devices with other sensor structures
may also be used.
[0163] FIG. 8(b) shows another sensor device comprising two
magnetic sensors structures spaced apart over a predefined distance
Ax, each sensor structure comprising one horizontal Hall element
(for measuring Bz) and two vertical Hall elements, one for
measuring Bx, and one for measuring By. The magnetic sensor device
820b is thus also capable of measuring three orthogonal magnetic
field components, namely (Bx1, By1, Bz1) at the first sensor
position P1, and (Bx2, By2, Bz2) at the second sensor position
P2.
[0164] FIG. 8(c) shows another sensor device comprising two
magnetic sensors structures spaced apart over a predefined distance
Ax, each sensor structure comprising only two horizontal Hall
elements arranged on opposite sides of an IMC disk and located on a
virtual line perpendicular to the X-axis. Each sensor structure is
capable of measuring two orthogonal components By, Bz at each of
the sensor locations P1, P2. It is an advantage of this sensor
device that it requires only four horizontal Hall elements instead
of eight.
[0165] FIG. 8(d) shows another sensor device comprising two
magnetic sensors structures spaced apart over a predefined distance
Ax, each sensor structure comprising one horizontal Hall element
and one vertical Hall element. Each sensor structure is capable of
measuring two orthogonal components By, Bz. It is an advantage of
this sensor device that it does not require integrated magnetic
flux concentrators, hence may be easier to produce.
[0166] FIG. 8(e) shows a variant of FIG. 8(a), and FIG. 8(f) shows
a variant of FIG. 8(b). The sensor devices of FIG. 8(e) and of FIG.
8(f) each comprise four sensor structures spaced apart in the X and
in the Y-direction, instead of only two sensor structures. These
devices are capable not only of measuring (Bx1, By1, Bz1) at P1,
and (Bx2, By2, Bz2) at P2, but are also capable of determining
spatial gradients of Bx, By and Bz at the two sensor locations P1,
P2 along the circumferential direction, i.e. (dBx/dy, dBy/dy,
dBz/dy).
[0167] The gradient signals dBy/dy and dBz/dy at P1 and P2 can then
be transformed into two sets of quadrature signals in a similar
manner as described above, e.g. using a set of linear or polynomial
equations with a relatively small number of coefficients, e.g.
predefined coefficients, which may be determined by simulation, or
by measurement, or after assembly. The coefficients may be stored
in non-volatile memory. A first angle .alpha.1 relative to the
inner ring, and a second angle .alpha.2 relative to the second ring
can then be calculated based on an arctangent function of the
quadrature signals. It is an advantage that the gradient signals
are highly insensitive to an external disturbance field, and thus
also the overall angular position will be highly insensitive to an
external disturbance field.
[0168] According to principles of the present invention, the
distance Ax between the sensor positions P1 and P2, and between the
sensor positions P3 and P4 are smaller than the distance "dt"
between two centrelines, e.g. at least 20% smaller. The distance
.DELTA.y does not need to be matched to the pole distances but is
used to determine gradient signals along the Y-direction. The value
of .DELTA.y may be substantially equal to .DELTA.x, but that is not
absolutely required, and it is also possible that .DELTA.y is
larger or smaller than .DELTA.x. The distance .DELTA.y is
preferably not too small, because otherwise the SNR of the
difference signal may become too small. The distance .DELTA.y is
preferably not too large, because otherwise the difference signal
will deviate more from a spatial derivative, which may decrease the
accuracy, and also because the cost of the sensor device increases
as the area of the semiconductor substrate increases. The skilled
person having the benefit of the present disclosure can find a
reasonable compromise.
[0169] In preferred embodiments, each of the distances .DELTA.x and
.DELTA.y are smaller than the track distance "dt", e.g. at least
20% smaller.
[0170] FIG. 8(g) shows a variant of FIG. 8(c) further capable of
measuring magnetic field gradient signals dBy/dy and dBz/dy. But
FIG. 8(g) can also be considered to be a variant of FIG. 8(e), not
capable of determining Bx or dBx/dy, which are not used in all
embodiments of the present invention.
[0171] FIG. 8(h) shows a variant of FIG. 8(d) further capable of
measuring magnetic field gradient signals dBy/dy and dBz/dy. But
FIG. 8(h) can also be considered to be a variant of FIG. 8(f), not
capable of determining Bx or dBx/dy, which are not used in all
embodiments of the present invention.
[0172] Functionally the sensor device of FIG. 8(a) and FIG. 8(b)
the same capabilities, the sensor device of FIG. 8(c) and FIG. 8(d)
have the same capabilities, the sensor device of FIG. 8(e) and FIG.
8(f) have the same capabilities, and the sensor device of FIG. 8(g)
and FIG. 8(h) have the same capabilities.
[0173] FIG. 8(a) to FIG. 8(h) show various examples of sensor
devices which can be used in embodiments of the present invention,
but the present invention is not limited thereto, and other sensor
structures may also be used, for example sensor structures
comprising magneto-resistive elements.
[0174] The predefined distance .DELTA.x may be a value in the range
from about 1.0 mm to about 3.0 mm, e.g. from about 1.5 mm to about
2.5 mm, e.g. equal to about 2.0 mm. The predefined distance
.DELTA.y may be a value in the range from about 0.5 mm to about 3.0
mm. As mentioned above, .DELTA.y (to be oriented in the
circumferential direction of the magnetic source) may be larger or
smaller than .DELTA.x (to be oriented in the radial direction of
the magnetic source).
[0175] FIG. 9 shows a high-level block-diagram of a sensor device
920 as can be used in embodiments of the present invention. In
fact, the hardware may be similar or identical to the hardware of
the devices described in patent publication EP3650816(A1) and in
patent application EP20191167.4, but the algorithm performed by the
controller 922 is different, as will be described in FIG. 10 to
FIG. 14. A brief description of the hardware is provided here for
completeness.
[0176] The position sensor device 920 of comprises a plurality of
magnetic sensor elements (in the example: SE1 to SE8), arranged in
a particular manner on a semiconductor substrate, e.g. as shown in
FIG. 8(a) to FIG. 8(f).
[0177] The position sensor device 920 further comprises a
processing circuit 922, for example a programmable processing unit
adapted for determining, e.g. calculating a set of values (By1,
Bz1, By2, Bz2) or a set of values (Bx1, By1, Bz1, Bx2, By2, Bz2)
based on the signals obtained from the sensor elements, e.g. by
summation or subtraction, and/or amplification, and/or
digitization, etc.
[0178] The processing unit 922 is further adapted for determining a
linear or an angular position according to one of the algorithms as
will be described further in FIG. 10 to FIG. 14. This position may
be provided at an output of the device, e.g. in a digital or analog
manner.
[0179] While not explicitly shown, the sensor device 920 typically
also comprises biasing circuitry, readout circuitry, one or more
amplifiers, analog-to-digital convertors (ADC), etc. Such circuits
are well known in the art and are not the main focus of the present
invention.
[0180] Devices used in the present invention comprise at least four
sensor elements, but they may comprise more than four sensor
elements, e.g. eight sensor elements or twelve sensor elements, or
sixteen sensor elements. The sensor elements may be chosen from the
group consisting of: horizontal Hall elements, vertical Hall
elements, magneto-resistive elements, e.g. XMR or GMR elements,
etc.
[0181] FIG. 10 shows a flow-chart of a method 1000 of determining a
position (e.g. a liner or angular position) of a sensor device
movable along a predefined path (e.g. linear or circular path)
relative to a magnetic source, wherein the magnetic source
comprises a first plurality Ni of magnetic pole pairs arranged
along a first track Ti having a first periodicity, and comprises a
second plurality N2 of magnetic pole pairs arranged along a second
track T2 having a second periodicity different from the first
periodicity, and wherein centrelines 213, 214 of the tracks T1, T2
are spaced apart by a predefined track distance "dt". The method
1000 comprises the following steps:
[0182] a) measuring 1001 at least two orthogonal magnetic field
components (e.g. By1, Bz1) at a first sensor location P1, and
measuring at least two orthogonal magnetic field components (e.g.
By2, Bz2) at a second sensor location P2, spaced from the first
sensor location P1 by a predefined sensor distance "ds" smaller
than the predefined track distance "dt" in a direction transverse
to the tracks;
[0183] b) determining 1002 the position of the sensor device (e.g.
linear or angular position) along the predefined path (e.g. linear
or circular or curved path) based on at least some of the at least
four measured magnetic field components (By1, Bz1, By2, Bz2).
[0184] Preferably one of the magnetic field components (indicated
as By in this application) is tangential to the direction of
relative movement, and preferably the other magnetic field
component (indicated as Bz in this application) is orthogonal to
the direction of relative movement. The latter is preferably also
orthogonal to the semiconductor substrate, although that is not
absolutely required.
[0185] The method may also comprise the step of: providing 1010 a
magnetic source comprising a first plurality (N1) of magnetic pole
pairs arranged along a first track T1 having a first periodicity,
and comprising a second plurality (N2) of magnetic pole pairs
arranged along a second track T2 having a second periodicity
different from the first periodicity, wherein centrelines 213, 214
of the tracks T1, T2 are spaced apart by a predefined track
distance "dt". This step is indicated as optional (dotted lines),
because it is not really part of the algorithm performed by the
processor of the sensor device, but rather a precondition or
prerequisite.
[0186] The position of the sensor device relative to the magnetic
source can be determined in several ways, a few of which are
described next:
[0187] In an embodiment, "determining said position based on at
least a subset of the measured signals" comprises: i) calculating
two sets of quadrature components as a linear combination of only
two magnetic field components, for example as depicted in FIG. 4,
and then ii) calculating or determining a first angle .alpha.1 by
using an arctangent function of the first set of quadrature
components (Bsin1, Bcos1), and calculating or determining a second
angle .alpha.2 by using an arctangent function of the second set of
quadrature components (Bsin2, Bcos2), and iii) by finding the
overall linear or angular position based on said first and said
second angle .alpha.1, .alpha.2 (e.g. by solving the
ambiguity).
[0188] In a variant of this embodiment, a non-linear transformation
is used to convert the measured signals into quadrature signals,
e.g. using a set of non-linear equations, e.g. second order or
third order equations.
[0189] In another embodiment, "determining said position based on
at least a subset of the measured signals" comprises: i)
calculating or determining a first angle .alpha.1 by using an
arctangent function of the first set of measured components By1,
Bz1, and calculating or determining a second angle .alpha.2 by
using an arctangent function of the second set of measured
components By2, Bz2, then ii) correcting the first angle .alpha.1
according to a first predefined, non-linear function (e.g. stored
in a non-volatile memory of the sensor device as a first
piece-wise-linear approximation), and correcting the second angle
.alpha.2 according to a second predefined, non-linear function
(e.g. stored in the non-volatile memory as a second piecewise
linear approximation), and iii) by finding the overall linear or
angular position based on said first and said second corrected
angles (e.g. by solving the ambiguity).
[0190] In yet another embodiment, "determining said position based
on at least a subset of the measured signals" comprises: i)
calculating or determining a first angle .alpha.1 by using a first
"modified arctangent function" of the first set of measured
components (By1, Bz1), and calculating or determining a second
angle .alpha.1 by using a second "modified arctangent function" of
the second set of measured components (By2, Bz2); and ii) by
finding the linear or angular position based on said first and said
second angle .alpha.1, .alpha.2.
[0191] The first angle .alpha.1 may be calculated (in step i) in
accordance with the following formula:
[0192] .alpha.1 =arctan(K1+K2*(Bz1/By1)), where Byl and Bzl are two
magnetic field components measured at the first sensor location P1,
and K1 and K2 are predefined constants; and the second angle
.alpha.2 may be calculated (in step i) in accordance with the
following formula: .alpha.2 =arctan(K3+K4*(Bz2/By2)), where By2 and
Bz2 are two magnetic field components measured at the second sensor
location P3, and K3 and K4 are predefined constants. The predefined
coefficients and/or the predefined constants may be determined by
design, by simulation, or by a calibration, and may be stored in a
non-volatile memory of the sensor device.
[0193] There are but three possible ways to determine the position,
but the present invention is not limited hereto, and other ways may
also be used.
[0194] While not shown in FIG. 10,
step a) may further comprise: measuring at least two orthogonal
magnetic field components (By3, Bz3) at a third sensor location
(P3) spaced from the first sensor location (P1) by a predefined
distance (.DELTA.y), and measuring at least two orthogonal magnetic
field components (By4, Bz4) at a fourth sensor location (P4) spaced
from the second sensor location (P2) by a predefined distance
(.DELTA.y) and spaced from the third sensor location (P3) by the
predefined sensor distance (ds); and step b) may further comprise:
determining magnetic field gradients dBy/dy and dBz/dy at the first
and second sensor location P1, P2 (e.g. as illustrated in FIG.
8(f)), and determining the position of the sensor device based on
these gradients (e.g. by first converting the gradients into
quadrature signals, and then taking an arctangent of these
quadrature signals to obtain .alpha.1 and .alpha.2, and then
resolving the ambiguity).
[0195] In addition to the advantages mentioned above, this method
offers the further advantage of being highly insensitive to an
external strayfield.
[0196] FIG. 11 shows a flow-chart of a method 1100 of determining a
position (e.g. a linear or angular position) of a sensor device
movable along a predefined path (e.g. linear or circular path)
relative to a magnetic source, wherein the magnetic source
comprises a first plurality N1 of magnetic pole pairs arranged
along a first track T1 having a first periodicity, and comprises a
second plurality N2 of magnetic pole pairs arranged along a second
track T2 having a second periodicity different from the first
periodicity, and wherein centrelines 213, 214 of the tracks T1, T2
are spaced apart by a predefined track distance "dt". This method
can be seen as a special case of the method of FIG. 10. The method
1100 comprises the following steps:
[0197] a) measuring 1101 at least two (e.g. By1, Bz1) or at least
three (e.g. Bx1, By1, Bz1) orthogonal magnetic field components at
a first sensor location P1, and measuring at least two (e.g. By2,
Bz2) or at least three (e.g. Bx2, By2, Bz2) orthogonal magnetic
field components at a second sensor location P2, spaced from the
first sensor location P1 by a predefined sensor distance "ds"
smaller than the predefined track distance "dt" in a direction
transverse to the tracks;
[0198] b) estimating 1102 a transverse position of the sensor
device relative to the magnetic tracks based on at least some of
the measured components;
[0199] c) determining 1103 the position of the sensor device based
on at least some of the measured components (e.g. By1, Bz1, By2,
Bz2) and based on the estimated transverse position.
[0200] In the system of FIG. 15(a) and FIG. 15(b) the transverse
position is a radial offset, e.g. an (unintended) offset from its
nominal (intended) mounting position for which the coefficients of
the equations of FIG. 4 were optimized. In the system of FIG.
15(c), the transverse position is a lateral offset.
[0201] In an embodiment, the transverse position of the sensor
device is estimated or determined based on one or more of the
following ratios: |Bx1|/|Bz1| or |Bx1|/|By1| or |By1|/|Bz1| or
|Bx2|/|Bz2| or |Bx2|/|By2| or |By2|/|Bz2| at one or more predefined
positions. The predefined position may be estimated using an
initial or predefined set of coefficients. In a variant, the
transverse position of the sensor device is estimated or calculated
based on a maximum value of one or more of said ratios, considered
over substantially the entire measurement range (e.g. over a full
rotation or over the full stroke), or may be based on the value of
the gradient |dBx/dx| at one or more angular positions or in an
angular subrange, or may be based on the maximum value of the
gradient |dBx/dx| over the measurement range. The gradient |dBx/dx|
may be calculated as |Bx1|-Bx2| or proportional thereto, where Bx1
is measured at the first sensor location P1, and Bx2 is measured at
the second sensor location P2. Looking back at the simulations of
FIG. 3(c), the inventors came to the insight that, even though the
signal Bx (oriented in the radial direction) seems to be completely
useless to determine the angular position, it can be very
advantageously used to determine radial offset, which in turn
allows to dynamically adjust the coefficients, which allows to
improve the accuracy despite said radial offset.
[0202] In other words, it is an advantage of the method of FIG. 11
that it allows the effect of position offset (as was discussed in
FIG. 7(a) and FIG. 7(b) to be mitigated. In this way, the accuracy
of the position sensor system can be improved, and the mounting
requirements can be relaxed, and the size of sensor device can be
reduced (because ds<dt).
[0203] In a variant of the method of FIG. 11, step a) comprises
measuring magnetic field components at four different locations P1
to P4 (e.g. as shown in FIG. 8(e) to FIG. 8(h)), and determining
magnetic field gradients, and determining the position based on
these gradients (e.g. similar as described in the variant of FIG.
10). This method not only offers the advantage of being highly
insensitive to position offset, but also offers the advantage of
being highly insensitive to an external strayfield.
[0204] FIG. 12 shows a flow-chart of a method 1200 of determining a
position (e.g. a linear or angular position) of a sensor device
movable along a predefined path (e.g. linear or circular path)
relative to a magnetic source, wherein the magnetic source
comprises a first plurality Ni of magnetic pole pair arranged along
a first track Ti having a first periodicity, and comprises a second
plurality N2 of magnetic pole pairs arranged along a second track
T2 having a second periodicity different from the first
periodicity, and wherein centrelines 213, 214 of the tracks T1, T2
are spaced apart by a predefined track distance "dt". This method
can be seen as a special case of the method of FIG. 10. The method
1200 comprises the following steps:
[0205] a) measuring 1201 at least two orthogonal magnetic field
components (e.g. By1, Bz1) at a first sensor location P1, and
measuring at least two orthogonal magnetic field components (e.g.
By2, Bz2) at a second sensor location P2, spaced from the first
sensor location P1 by a predefined sensor distance "ds" smaller
than the predefined track distance "dt" in a direction transverse
to the tracks;
[0206] b) calculating 1202 a first set of quadrature components
Bsinl, Bcosl and a second set of quadrature components Bsin2, Bcos2
based on at least some of the measured components (e.g. By1, Bz1,
By2, Bz2), using a set of equations with a predefined set of
coefficients (e.g. a set of only eight predefined
coefficients);
[0207] c) determining 1203 the position of the sensor device based
on the first and second set of quadrature components Bsin1, Bcos1,
Bsin2, Bcos2.
[0208] In an embodiment, step c) comprises calculating a first
angle .alpha.1 and a second angle .alpha.2 using an arctangent
function and finding an overall angle .alpha. by resolving the
ambiguity related to the first periodicity and the second
periodicity.
[0209] In a variant of the method of FIG. 12, step a) comprises
measuring two orthogonal magnetic field components in at least four
different sensor locations P1-P4, and determining magnetic field
gradients; and step b) comprises: calculating a first and second
set of quadrature signals based on these gradients. This method
would be highly robust against an external disturbance field.
[0210] FIG. 13 shows a flow-chart of a method 1300 of determining a
position (e.g. a linear or angular position) of a sensor device
movable along a predefined path (e.g. a linear or circular path)
relative to a magnetic source, wherein the magnetic source
comprises a first plurality Ni of magnetic pole pairs arranged
along a first track T1 having a first periodicity, and comprises a
second plurality N2 of magnetic pole pairs arranged along a second
track T2 having a second periodicity different from the first
periodicity, and wherein centrelines 213, 214 of the tracks T1, T2
are spaced apart by a predefined track distance "dt". This method
can be seen as a special case and/or as a variant or combination of
the methods of FIG. 10, FIG. 11 and FIG. 12. The method 1300
comprises the following steps: [0211] a) measuring 1301 at least
two (e.g. By1, Bz1) or at least three (e.g. Bx1, By1, Bz1)
orthogonal magnetic field components at a first sensor location P1,
and measuring at least two (e.g. By2, Bz2) or at least three (e.g.
Bx2, By2, Bz2) orthogonal magnetic field components at a second
sensor location P2, spaced from the first sensor location P1 by a
predefined sensor distance "ds" smaller than the predefined track
distance "dt" in a direction transverse to the tracks; [0212] b)
estimating 1302 a transverse position of the sensor device relative
to the magnetic tracks based on at least some of the measured
components; [0213] c) determining a set of coefficients or
selecting 1303 a set of coefficients from a plurality of predefined
sets, based on the estimated transverse position. These predefined
sets may be stored in a non-volatile memory of the device.
Depending on the estimated transverse position one of the
predefined sets may simply be selected, or an interpolation between
two sets of coefficients could be performed. [0214] d) calculating
1304 a first set of quadrature components Bsinl, Bcosl and a second
set of quadrature components Bsin2, Bcos2 based on at least some of
the measured components (e.g. By1, Bz1, By2, Bz2), using the set of
coefficients determined in step c); e) determining 1305 the
position of the sensor device based on the first and second set of
quadrature components Bsinl, Bcosl, Bsin2, Bcos2.
[0215] It is an advantage of this method that the set of
coefficients is not fixed, but is dynamically adjusted, depending
on the estimated transverse position. This offers the advantage of
mitigating the effect of lateral offset (e.g. due to mechanical
tolerances), and thus may the position error (e.g. as discussed in
FIGS. 7(a) and 7(b)).
[0216] It is noted that the transverse position need not be
measured in each and every particular position but is a long-term
effect. It is therefore possible to determine the estimated
transverse position "between" two actual position measurements,
e.g. during an in-situ self-calibration-procedure or the like,
optionally taking into account historical data, such as maximum
signal values over the entire measurement range, or one or more of
the above mentioned ratios (e.g. |Bx|/|Bx|, etc.). In other words,
step b) and step c) need not necessarily be performed between step
a) and step e), and step b) and step c) need not be performed every
executing of the method of FIG. 13, but may be skipped. Of course,
if historical data is stored in the non-volatile memory, extra
memory space needs to be allocated.
[0217] FIG. 14 shows a flow-chart of a method 1400 of determining a
position (e.g. a linear or angular position) of a sensor device
movable along a predefined path (e.g. linear or circular path)
relative to a magnetic source, wherein the magnetic source
comprises a first plurality Ni of magnetic pole pairs arranged
along a first track Ti having a first periodicity, and comprises a
second plurality N2 of magnetic pole pairs arranged along a second
track T2 having a second periodicity different from the first
periodicity, and wherein centrelines 213, 214 of the tracks T1, T2
are spaced apart by a predefined track distance "dt". This method
can be seen as a special case of FIG. 10, and/or as a variant or
combination of the methods of FIG. 11 to FIG. 14. The method 1400
comprises the following steps:
[0218] a) measuring 1401 at least two (e.g. By1, Bz1) or at least
three (e.g. Bx1, By1, Bz1) orthogonal magnetic field components at
a first sensor location P1, and measuring at least two (e.g. By2,
Bz2) or at least three (e.g. Bx2, By2, Bz2) orthogonal magnetic
field components at a second sensor location P2, spaced from the
first sensor location P1 by a predefined sensor distance "ds"
smaller than the predefined track distance "dt" in a direction
transverse to the tracks T1, T2;
[0219] b) calculating 1402 a first set of quadrature components
(Bsinl, Bcosl) and a second set of quadrature components (Bsin2,
Bcos2) based on at least some of the measured components (e.g. By1,
Bz1, By2, Bz2), using a predefined set of coefficients or constant;
(for example based on an initial, predefined set of
coefficients);
[0220] c) estimating 1403 a linear or angular position based on the
first and second set of quadrature components (Bsin1, Bcos1, Bsin2,
Bcos2);
[0221] d) estimating 1404 a transverse position of the sensor
device relative to the magnetic tracks (T1, T2.degree. based on at
least some of the measured components, optionally taking into
account the estimated linear or angular position of step c);
[0222] e) determining a set of coefficients, or selecting 1405 a
set of coefficients from a plurality of predefined sets, based on
the estimated transverse position, optionally taking into account
the estimated linear or angular position of step c);
[0223] f) calculating 1406 a third set of quadrature components
(Bsin3, Bcos3) and a fourth set of quadrature components (Bsin4,
Bcos4) based on at least some of the measured components (e.g. By1,
Bz1, By2, Bz2), using the (new) set of coefficients of step e);
[0224] g) determining 1407 a corrected position (e.g. linear or
angular position) of the sensor device based on the third and
fourth set of quadrature components Bsin3, Bcos3, Bsin4, Bcos5.
[0225] As mentioned above, it is not required to perform steps d)
and e) each and every execution. It suffices for example to perform
steps d) and e) only now and then (e.g. once every second, or once
every minute, or even once every hour, depending on the
application), because lateral offset is related to mispositioning,
which is typically a long-term effect. Furthermore, it is not
required that steps d) and e) are performed for each and every
(linear or angular) position, but in some embodiments of the
present invention, they are only executed within certain angular
ranges, or at certain angular positions (with some tolerance
margin).
[0226] Reference is made to FIG. 16 which is a duplicate of FIG.
3(c), with information added. Indeed, when trying to find a
solution to detect the radial offset, the inventors discovered that
the simulation of FIG. 3(c) surprisingly also shows "unexpected
regions" which seem to appear especially between the two circles
defined by the first and second sensor location P1, P2. This was
not at all expected. In fact, ten interesting angular locations are
indicated by letters A to K, which may be particularly interesting
for determining not only the presence but also the amount of radial
offset based on the signal |Bx1-Bx2| or Bx1-Bx2)/(Bx1+Bx2). Indeed,
in locations A, B, C, D, the radial gradient should be
approximately equal to zero, if the sensor device is not radially
shifted (with respect its original position). If the sensor device
is radially shifted inwards, the signal at the second (outer)
sensor location P2 will be larger (in absolute value) than the
signal at the inner sensor location P1. Likewise, if the sensor is
shifted radially outwards, the signal at P2 will be smaller in
absolute value than the signal at P1. Thus, at the angular
locations A, B, C or D, the radial gradient dBx/dx is an excellent
indicator for the radial shift of the sensor device. More in
particular: (i) comparing this magnitude with a predefined
threshold can be used to detect radial shift, (ii) the sign of
dBx/dx is an indicator for the direction of the radial shift of the
sensor device (inwardly or outwards), (iii) and the amplitude of
dBx/dx, or the relative amplitude (Bx1-Bx2)/(Bx1+Bx2) is an
indicator for the amount of radial shift. But the locations A, B,
C, D may not be the only interesting locations, since also at the
angular locations F, G, H, J the amplitude of the radial gradient
will strongly vary in case of radial shift. Thus in these
locations, the radial gradient dBx/dx or the relative gradient may
also be used to determine the amount of radial shift of the sensor
device. The angular locations E and K may also be used, but seem
less useful than the the other angular positions. It is of course
also possible to combine the information obtained from various
angular locations in order to determine the radial offset.
Referring back to FIG. 14, it can now be better understood that in
a particular embodiment of this method, step d) comprises making
use of the radial signal Bx, or of the spatial gradient of that
signal dBx/dx or of the ratiometric signal (Bx1-Bx2)/(Bx1+Bx2).
[0227] For completeness it is repeated that the signal dBx/dx is
not the only possible way to determine radial offset of the sensor
device, and there may be other ways to determine radial offset, as
already stated above, e.g. based on on the ratio, or the maximum
ratio of the signals By, Bz.
[0228] FIG. 15(a) shows an angular position sensor system 1500a
comprising a magnetic source 1510a comprising two concentric tracks
located in a single plane, and a sensor device 1520a arranged above
or below that plane. In the example, the first track T1 is formed
by an inner ring having eight pole pairs, and the second track T2
is formed by an outer ring having ten pole pairs. These rings are
preferably axially magnetized. The sensor device "sees" eight poles
when moving over the inner ring, and "sees" ten poles when moving
over the outer ring (or when the sensor device is stationary and
the magnetic source is rotated). The centrelines 223, 224 of these
tracks are two concentric circles having a different radius. The
centrelines 223, 224 are spaced apart by a track distance "dt" in
the radial direction. The distance between the sensor locations P1
and P2 of the sensor device is "ds", which is smaller than the
track distance "dt", preferably at least 20% smaller. The first and
second sensor location P1, P2 are preferably located on a virtual
line X which is radially oriented with respect to the magnetic
source. There may be an uncoded region, e.g. in the form of a
circular groove situated between the tracks T1, T2, optionally
filled with a non-magnetic material.
[0229] FIG. 15(b) shows an angular position sensor system 1500b
comprising a magnetic source 1510b comprising two cylindrical
tracks having a same radius, and a sensor device 1520b arranged as
a satellite movable around these cylindrical tracks (or vice
versa). The centrelines 223, 224 of the first and second track T1,
T2 is a first circle and a second circle, a portion of which is
shown in FIG. 15(b). These centrelines 223, 224 are spaced apart by
a track distance "dt" in the axial direction A. There may be an
uncoded region, e.g. in the form of a circular groove situated
between the tracks T1, T2, optionally filled with a non-magnetic
material.
[0230] FIG. 15(c) shows a linear position sensor system 1500c
comprising a magnetic source 1510c comprising two parallel, linear
tracks T1, T2 located in a single plane, and a sensor device 1520c
arranged above or below that plane. Also shown is an orthogonal
coordinate system connected to the magnetic source, comprising a
height direction H, a longitudinal direction L, and a transverse
direction T. In the example shown, the first track T1 is formed by
a first multi-pole magnet having eight pole pairs, and the second
track T2 is formed by a second multi-pole magnet having ten pole
pairs. These magnets are preferably magnetized in the height
direction H. The sensor device 1520c "sees" eight poles (four North
poles and four south poles) of the first track T1, and ten poles of
the second track T2, when moving over the magnetic structure in the
longitudinal direction L (or vice versa). The centrelines 223, 224
of these tracks are two parallel lines, spaced apart by a track
distance "dt" in the transverse direction T. There may be an
uncoded region, e.g. in the form of a circular groove situated
between the tracks T1, T2, optionally filled with a non-magnetic
material.
[0231] The position sensor systems of FIG. 15(a) to FIG. 15(c) are
of course only examples, and the present invention is not limited
thereto, but only by the claims. For example, the number of pole
pairs of each track may be different from those illustrated in the
examples, and the sensor device may have other sensor structures,
e.g. as illustrated in FIG. 8(a) to FIG. 8(h), or other suitable
sensor structures.
[0232] FIG. 16 is already discussed above, when discussing the
method of FIG. 14.
* * * * *